Fabricated metal structure



July 9, 1946 'M wA-rTER FABRICATED METAL STRUCTURE 4 Seets-Sheet 1 Filed June 16, 1945 NVENTOR Michael Waiter ATTORNEY July 9, 1946.

M. wAT'rER FABRICAIED METAL STRUCTURE AFiled June 16, 1945 4msheets-sheet 2 Ammann INVENToR Michael Waiter.

ATTORNEY July 9,'1'946.

M, WATTER FABRICATED METAL STRUCTURE Filed June 16, 1943 4 Sheets-Sheet I5 y 60 INVNTOR f Mic had Waiter July 9, 1946. M. wA'rTx-:R'

FABRICATED METAL STRUCTURE 4 sheets-sheet 4 Filed June 16, 1943 Illllllllllllllllllllllllllllllll! INVENTOR Michal Waiter.

ATTORNEY mr. 0E

Patented July 9, 1946 UNITED STATE p FABRICATEDA METAL STRUCTURE Michael Watten Philadelphia, Pa., assigner to Edward Philadelphia, Pa., vania G. Budd- Manufacturing Company,

a corporation of Pennsyl- Application June 16, 1943, SerialNo. 491,034

This invention relates to fabricated metal structures, particularly to an improved construction and method of assembly of airfoils. and has for an object the provision of improvements in this art.

In the fabrication of skin-covered frame-supported structures, such as airfoils, from sheet metal, it is very desirable and economical to prepare sub-assemblies, which include portions of the covering skin and 'associated parts, and to unite these sub-assemblies to form larger subassemblies suitable for later forming unit groups. In this way the manufacturing operations may be Widely divided` among the greatest number of workers to secure the greatest speed of manufature and the most favorable inspection metho The primary object of the present invention is to provide a structure `of multi-part construction in which the parts comprising sub-assembly units are so arranged as to afford maximum facility for uniting such' parts as ribs, stringere, and the like to the skin sheets, and the subsequent assembly and joinder of the sub-assembly units to form the completed unit.

Another object is that of providing sub-assembly units, such as bi-partite units, in which the parts comprising the same are so related that when associated and assembled together in a iinal assembly unit they afford a light Weight unit of great strength capable of efficiently transferring the various stresses encountered in use.

The abovementioned and other objects and advantages of the invention will be apparent from the following description of certain exemplary embodiments thereof which are illustrated in the accompanying drawings, wherein:

11 Claims. (.Cl. 244-124) Fig. 1 is a side elevation of an airplane tail iin y embodying the invention;

Fig. 2 is an enlarged horizontal section taken on the line 2-2 of Fig. l; i

Fig. 3 is a pre-assemblyview of theparts shown in Fig. 2;

. Fig. 4 is an enlarged partial vertical section taken on the line 4--4 of Fig. l

Fig. 5 is an enlarged fragmentary perspective View of parts shown within the enclosed area 5 of Fig. 2;

Fig. 6 is an enlarged vertical section of the fln tip taken on the line 6 6 of Fig. 1;

Fig. 7 is an enlarged vertical section taken on the line 1--1 of Figs. 1 and 2;`

Fig. 8 is a section similar to Fig. 2 but showing a modification in a horizontal-stabilizer fin;

Fig. 9 is an enlarged section taken on the line 9-9 of Figs. 8 and 11;

Fig. 10 is an enlarged section taken on the line ||l-|0ofFig.8; and

Fig. 11 is an enlarged fragmentary perspective -2 view of parts shown within the enclosed area Il of Fig. 8. f

The invention is illustrated in connection with an airfoil for aircraft, as for example, a wing, aileron, 1in, rudder, stabilizer, elevator, or the like; and specically a tail fin in one embodiment and a horizontal stabilizer fin in another.

According to the present invention, the airfoil, certain forms of which are shown herein for the purpose of illustration, is made in mating parts such as half-shells which are later secured together to form a final assembly unit. Each parti-shell includes the skin, various skin stillen ers, and rib elements, together with spar elements near the nose or leading edge and provisions for spar elements near the trailing edge. The parts are so formed and arranged as to afford easy and rapid iinal assembly, as for example by ther use of spot welding tongs inserted from one open edge of the airfoil.

Referring particularly to Figs. l and 4, the iin illustrated herein comprises aleading edge or nose section 29,' a. trailing section' 2|, a tip section 22, and a fuselage fairing section 23. The fairing section may be formed as a separate sub-unit which is attached later, hence the tail iin unit will be considered as a complete sub-unit without the fairing'- section. The fin includes a nose spar structure and a rear spar structure 2li.4

These are both indicated by dotted lines in Fig. 1. The nose spar structure is shown in Figs. 2 and 3, but the rear spar is omitted in Fig. 3because it is convenient to insert this from the trailing edge after the half-shell sub-assemblies have been secured together.

As indicated for the full fin in Fig. i and as shown for a representative portion of the iin in Fig. 4, the airioil includes the thin gauge metal skin which is rigidied by parallel rib-like elements which may-be of the-same or diierent types. As here shown, diiierent types of ribs are employed. There are small stiieners or formers 3l, open truss ribs 32, and full-web ribs 33. Where the rudder hinge brackets 35 are located the heavy full-web rib construction 33 is employed. At the base of the fin an especially 4 heavy bulkhead type of rib construction 35 is employed `but as thisl is similar in principle to the other heavy ribs it need not be specifically illustrated or described herein. Since it is not enclosed within the airfoil but is exposed at one end it may even be made as a single piece welded through outturned flanges to the assembly.

As shown in Fig. 1, the heavy ribs 32 rand 33 are continued into the nose portion 20 as rib elements 40. Referring also to Fig. 2, skin stiiening stringers 4I, which are disposed transversely of the rib elements are also provided in the nose section. At the leading edge of the nose section the skin 3D is bent to-form stringere 42 contour of the finally assembled unit.

As shown in Figs. 1 and 6, the n Vtip 22 is provided with ribs 45 which are parallel to the ribs 32, 33 of the main fin section 2|, which ribs 45 have full webs like the ribs 33. The tip is also provided with parallel skin stiffening formers or stringers 46 arranged parallel to the ribs 45. In addition, the tip is provided with-rib elements 41 which extend at right angles to the ribs 45, 46. The rib elements 41 may be divided longitudinally to avoid the ribs 45 and laterally to leave open spaces in the center. The skin may be -formed to provide nose stiiening elements 42 and the nose may be covered by a closure sheet l 43, as above described for the leading edge.

A s shown in Fig. 1, the fairing section 23 is provided with ribs 43 which are parallel to and lpreferably aligned with the ribs` 32, 33 of the main n section 2|.` The fairing section also includes a heavy base rib or bulkhead 50 for anchorage to the fuselage, as by bolts 5|. At the, leading-edge it is provided with vertical stiiening means 52 and at the rear with a spar element 53 which supplements the front spar 25 at the 1 lower end. The ,fairing section in fully assemiin assembled condition is secured to the main bly by screws 54.

As shown in Figs.. 2, 3 and 4,' the full-webbed ribs 3 3 are formed by flanged webs 33a which are welded to the skin at their outer edges, as along flanges 5|), and are welded together along their overlapping edges interiorly, as indicated at 6|. 0n the inner edges the webs arev strengthned by c marginal anges 63. Intermediately l' they are strengthened by'longitudinal beads 64 and by anges `surrounding lightening openings 65, (Fig. 5). Transversely the webs are stiilened byilanged hat-shaped struts 56 which are ar- AThe webs a of the tip ribs 45 (Fig. 6) are similar to the webs 33a of the heavy ribs 33 and the same reference numerals are used'for their y parts, but the Abeads 64 and struts 66 may be omitted. They may be reinforced on their outer edges by L-shaped stringers 60h which are welded thereto and to the skin. A reinforcing plate 45h is secured beneath one of the ribs 45. The skin may be made in sections which are connected by the plate 45h prior to assembly.

The nose spar 25 (Figs..2, 3, 5 and '1) comprises flanged channel chords 25a which are weldedthrough their backs tothe skin 3|), a strengthening plate 25h, if desired, being interposed between each channel member and the skin. The skin may be made in sections which are connected by the plate 25h prior to assembly. The plates 25h are wider than the backs of the channel chords 25a and the adjacent rib webs are suitably joggled to receive the extended edges of the plate. A closure plate 14 is welded to the interior of each channel chord 25a and with it in effect forms a closed box spar chord on each side adjacent the skin which vincreases the torsional resistance of the channel chords 25a. There is left inside each box chord thus formed a wider channel and at intervals therein there are secured cupped strut elements 15 arrangedback to back and welded together through their overlapping portions in the iinal assembly, as at 16. The spar -strut elements 15 are preferably aligned with the adjacent rib element. The strut elements maybe secured to the plate 14 before the plate is welded to the channel member 25a; and the latter is welded to the backing plate 25h and preferably also to the skin before the inner plate 14 is welded in. The side walls of the channel member 25a are welded tothe end flanges 13 and 11 of adjacent rib elements 40V and 33a. As thus formed, the nose spar 25 is open between the ribs 32, 33

- to permit welding tongs to be'. inserted from the ranged on opposite sides of the -webs and have 4 overlapping ends which are welded together when the webs are Joined along their overlapping edges.

'I'he open ribs 32 comprise flanged webs 32a secured through outer flanges 60a' to the skin sheets30 vand marginally flanged interiorly as at 63a and interconnected at-intervals Vby hatsection struts 35a' which are' spot welded thereto and which overlap each other and are spot welded together, as at Ila, in the final assembly operationfthe spacing of the struts 66d being someglglatgomparable to that of then struts 66 of the As shown in Figs. 2 and 3, ythe nose rib elements y 40 are Iformed of two webs 43a which overlap at their front extended ends where they are kwelded together, as indicated at 33.A The webs are provided with outer flanges 1l welded `to the skin 34, front end flanges 1| also welded to the skin,

' interior flanges 12 in, their spaced-apart portions,

and rear flanges 13 which are welded tothe front spar chords 25. y

The webs 41a of the vertical .ribs 41 of the tip (Fig. 6) aref very similar to the webs 44a of the nose edge ribs 30 .and their parts are designated by the 'same reference numerals. The supplemental web elements 41h are hanged on all edges,

as by cupping, and are secured through their' outer iianges to the skin 33. j

rear openside to secure the nose webs 40a and the spar strut elements 15v together.

The rear spar 25 includes a. web 19 andcap the skin after the spar has been secured for the attachmentrof a rudder arch (not shown).

In Figs. '8 to 1l a modification is shown. Here the rib |33 4includes the webs |33a which are provided with outer flanges welded to the skin |30 and inner overlapping portions which are welded together as at |-6|. ened by interior flanges I 63, transverse .beads |64, and Z-shaped stifi'eningstruts |66. The beads and ribs are disposed on opposite sides for the respective webs so as to avoid obstructing ,the overlapping faces of the webs which are to -be welded together. l

The nose rib elements |40 comprise the webs |40a which overlap at the front end for welding, as at |69. ,The webs Illia, each includes an outer flange |10, a front end' ange |1|, strengthening beads |12, and notches |13 lin the outer edge to receive the skin stiiening stringere |4|. Nose stringers |42 are Secured to the skin sheets and after their forwardly exposed flanges 'are welded together the space is covered by a closure sheet |43. The nose section may be covered by sheets 30a which are non-integral witl the main sheets 15 |30 and are overlapped and welded theretoat They are strengthillustrated.

Spar chords |2511, are of each skin cover.

secured to the inner side These members are of flanged-channel or hat shape, as shown. The rib either before or after the vmain assembiyis' vsecured to the anchorage structure.

webs |33a extend forwardly past the front spar location and are recessed as at |34 to span the chords |25a. Reinforcing gussets |31, suitably flanged, are provided at the rib recesses |34. At

. the front end, the webs |33a are provided with ilanges |11. Heavy channel-sectioned spar struts |39 are welded to opposite sides of the respective gether.

webs |330. at the front end, which struts are cut away at a bevel at the adjacent ends to permit welding through the overlapping Webs in the final assembly operation.

The characteristics of the structure hereby provided are such that the fabrication of the airfoil is greatly facilitated. Each half is formed in a contoured form-fitting jig which is a replica of the shape of the corresponding part of the final airfoil. For example, considering the first embodiment of Figs. l. to '17, three skin sections are welded together through the plates h (Figs. 2, 3 and 5) and 45h (Fig. 6). An alternative step here would be to use a single sheet for each side and to weld the plates to it, These skin assemblies are placed in form-fitting jigs and the shaped skin formers 3|, 4| and 48 Welded in. The channel chords 25a, are then welded in place. The nose ribs 40, the main section ribs 32, 33 and the tip ribs 45y 4l are welded in place, and the elements 40, 32, and 33 are welded to the channel chords 25a. Next the channel, closure plates 14 are welded into the widened space of the channelchords 25a. The spar struts 'l5 may have already been attached to the plates 14. At

the outer edges they are welded with the closure plates to the outwardly and upwardly extending side iianges of the channel chords 25a. They are aligned with their correspondingr rib elements.

The half-,shells arev placed -in a full airfoil jig, and when properly clamped in position the juxtaposed overlapping rib elements are welded together. There is enough overlap in each rib and in the spar struts 'l5 to provide for this. The parts to be welded together are all in alignment, hence it is easy to make the welds by welding tongs inserted from the open rear edge. Bent welding tongs are required for the tip ribs 41, but since these ribs are open behind the nose ends, it is easy to insert the welding tongs from the rear.

The flanges of the nose strirgers`42 are spot welded together from outside the assembly.

' Thereafter, the nose skin sheetsdS are secured The structure-shown in the modiiication of Figs. 8 to 11 is so similar to the first form that no special explanation of the method of fabrication is needed. It may be noticed, however, that the second modication makes it somewhat easier to assemble the nose section half-shells to- A permissible variation in assembly procedure with either form, though requiring some special welding tools and varied procedure in the rstform, is to secure the two nose half-shells together before they are secured to the main section half-shells.

It is thus seen that the invention provides an improved airfoil lconstruction and an improved method of fabricating the same, all leading to economy and speed of production thoroughness of inspection, and strength, lightness and dependability in use.` While spot welded connec-V tion may have various embodiments within the relative chordal width of the particular airfoil being constructed. v

The rear spar 26 is inserted and secured from the rear after the airfol has been assembled. The full width of the rear end of the airfoil is thus left open for the insertion of tools until the rear spar is brought in. The. edge stiffeners 93, the hinge brackets 35, and the arch may be placed later.' As an alternativa-the edge stiffeners 83 may be placed before the rear spar, the skin being suiciently flexible to permit the spar to be inserted past the stiffeners.

The fairing section( 23 is also introduced later,

each including a covering aft rib elements having a junction with the fore limits of the prior art and the scope of the subjoined claims.

What is claimed is:

1. A metallic construction comprising in combination, two separately fabricated' parti-shells, skin, fore rib elements,

rib elements, transverse spar chords at the junction between the fore rib elements and the aft rib elements, and spar connecting strut elements at thesaid junction, said rib elements and said spar strutelements being aligned for each `rib and the elements of the parti-shells being overlapped in therfinal assembly and secured together through their overlapping portions by shear elements inside the skin-covered assembly thus formed, the spar being open between its strut elements and between the ribs from one end to the other in the assembly toprovicle access from the edge for connecting the fore rib elements, the spar strut elements and the aft rib elements, as by rib-straddling welding tongs passed over an end of a rib.

2. A metallic construction comprising in combination, two separately fabricated parti-shells each including a covering skin, nose ribs, each including elements which overlap between their planes at their front ends and stand spacedapart at their rear ends when the parti-shells are assembled, main rib elements which overlap between their planes along their length when the parti-shells are connected, transverse spar chords at the junction of the nose and main ribs which the parti-shells are assembled, and spar connecting strutl elements aligned with s aidrib elements which overlap between their planes when the parti-shellsv are assembled, the overlapping portions of said rib elements and spar strut elements being connected through their planes in the assembly.

3. AA metallic construction comprising in combination, a nose section including spaced ribs each formed of plate-likepart-ribs welded together through overlapping portions, and a metal skin covering on said ribs; a main section including spaced ribs each formed of .plateylike partribs welded together through overlapping portions, and a metal skin covering on said main section ribs; and a transverse spar between said `sections, said spar including spaced channelgether inside from the trailing edge.

4. A metallic interiorly framed exterlorly covered structure, comprising in combination, chord- Wise extending nose ribs and main ribs and a transverse spar between them, said sparl including channel-shaped chord elements .or cap -strips having in section a back and spaced sides and an open front secured to the skins through their backs leaving their open fronts facing each other, said chord elements having closing chordv plates over theirinner 'open fronts, and spar strut elements secured to said chord plates of each chord element, said. strut elements being overlapped and secured together in the overlap.

5. A metallic interiorly framed exteriorly covered structure, comprising in combination, chordwise extending-nose ribs 'and main ribs and a mtransverse spar between them, said spar includ-v ing channel-shaped chord elements or cap strips having in section a back and spaced sides and an open front secured to the skins through their backs leaving their open fronts facing ,each other, said chord elements having closing chord plates over their inner open fronts, and spar strut elements secured to said chord plates of each chord y element, said strut elements being overlapped and secured together in the overlap, said spar strut elements having their overlapping surfaces arranged transversely of the spar direction an parallel to the rib direction.

overlapping plate-like partsy secured together- `through their overlapping portions, and each part of each lmain rib element being secured at its leading end tothe adjacent stringerelement,

and a channelled` metallic member rigidly secured to each rib element part at the leading end stantially between said opposed Stringer elements,V I

the nose rib elements being secured to the stringe:` elements.

8. In an airfoil having a nose portion, a main portion, and a metallic Skin covering extending over the opposite sides of said portions, a pair oi opposed spanwise extending through-running channelled metallic Stringer elements secured to 6. In an airfoilhaving a nose portion, a, main portion, and a metallic skin covering extending over the opposite sides of said portions, a pair of opposed spanwi'se extending through-running channelled metallic stringer elements secured to the inner surfaces of said covering, one at each side'between said nose andmain portions, metallic main rib elements extending chordwise from said Stringer elements throughout substantially thechordwise extent of said main portion,- said main rib elements each embodying overlapling plate-like parts secured together through their overlapping portions, and each part of each main rib element being secured at its leading end to the adjacent Stringer element," and a channelled metallic member rigidly secured to each rib element part at the leading end thereof, said channelled members overlapping each other with and being secured together through said rib element parts and extending substantially between said opposed Stringer elements.

'7. In an airfoil having a nose portion, a main portion, and a metallic skin covering extending over the opposite sides of said portions, a. pair of opposed spanwise extending through-running channelled metallic Stringer elements secured to the inner surfaces of said covering, one at each side between said noseand main portions, me; tallic main rib elements extending chordwise Afrom said Stringer elements throughout substantially the chordwise extent of said main porthe inner surfaces of said covering, one at each side between said nose and main portions, metallic main rib elements extending chordwise from .said Stringer elements throughout substantially the chordwise extent of said main portion, said main rib elements each embodying overlapping plate-like parts secured together through their overlapping portions, and each part of each'main rib element being secured at its leading end to the adjacent Stringer element, and a channelled metallic member rigidly secured to eachrib element part at the leading end thereof, said channelled members overlapping eachother with and being secured together-through said vribfelement parts and extending substantially between said opposed Stringer elements, the nose rib elements'A being secured to the Stringer elements and to the main rib element parts.

9. A metallic structure comprising a rst and second spaced covering skins and havingvat least one open edge, laterally spaced rib members extending in a first direction from said open edge and Lsecured to the iirst of said skins, complementary spaced rib members extending from the second skinand each generally paralleling its corresponding first mentioned rib member, means connecting said rib members, said means including elements overlapping in planes parallel to said rib elements, a spar member secured to theirst skin and extending in a direction transverse to the first direction, a complementary v f spar member secured to the second skin and ex- -tending generally parallel to the rst spar member, means connecting saidspar members, said last-mentioned means. including' elements overlapping in planes parallel to said rib elements, whereby the overlapping elements of the rib member connectingvmeans and the overlapping elements of the spar member connecting means are disposed in parallelism sc as to be readily v secured together through said open edge of the structure. 4 10. A' metallic structure as set vforth in claim i 9 further characterized by the fact that the conhecting elements of the spar members are spaced apart sufciently along the length of the spar members to provide working access between them.

11. A metallic structure as set forth in claim 91 which includes rib members on both sides of the spar members, said connecting .elements of the spar members being spaced apart sulciently along the length of the spar members to provide working access between them.

'menant wanna. 

